THREAD allows electrical, optical and structural elements to be introduced throughout an additively manufactured component during the build process. A patent-pending technology, THREAD enables the manufacturing of components with in-built, continuous connectivity and additional functionality passing through the X, Y and Z axes.

So far, the fully automated THREAD process has been successfully demonstrated on machines used for 3D printing polymer components, though AMRC suggests it is suited to a variety of platforms.

“THREAD has scope to simultaneously add multiple industry-recognised threads of differing materials into one component, giving the component additional functions. This will open AM up to a greater variety of uses,” said Mark Cocking, AMRC Development Engineer and AM specialist. “The development of this process is a potential game-changer. It could be used across many sectors such as medical, aerospace and automotive; where weight and size of components is critical or where components would benefit from integrated data transfer and the protection of sealed connective tracks.”

Cocking and his colleagues at the AMRC are confident THREAD will be a significant advantage in the manufacture of components requiring encapsulated electronics. In particular, medical prosthetics, consumer electronics and structural components that require electrical connections have been outlined as target areas. For example, until now electrical connections would have had to have been secured externally from the component they would operate as part of. The nature of the ‘sealed’ conductive tracks could also be of benefit for components which may be sensitive to contamination from debris, corrosion or impact.

Cocking adds that THREAD has the potential to be developed as an add-on technology for existing AM platforms, and perhaps incorporated into next generation AM technologies too. Meanwhile, Chris Iveson, who is driving the commercialisation of the technology, reveals that THREAD was developed with the consultation of AMRC’s industry contacts.

“We see THREAD transforming the functionality of additively manufactured components. Feedback from our contacts in various industries indicates a real need for this capability, with new potential applications being discussed daily. This is a great example of the AMRC using its unique expertise to solve real industry problems.”

While AMRC continue to develop the THREAD process for various commercial markets, manufacturers of 3D printers, as well as industrial users of 3D printing processes, are being encouraged to contact the AMRC Design and Prototyping Group.